Effect of Processing Parameters on Friction Stir Welded HSLA-65 Charpy V-Notch Impact Toughness

Abstract This paper deals with the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were investigated implementing a full factorial design of experiments. During the welding process, axial and transversal forces were continuously measured using a dedicated sensed fixture aiming at the correlation of this processing parameter with the quality of the achieved joints. The reported outcomes showed a very narrow processing window in which it was possible to avoid the formation of defects while the formation of an hook was observed for all the joints welded. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. A correlation between the process parameters and the forces arising was also attempted. The final microstructure of the joints was studied and explained and also compared with the microhardness results.

Download Full-text

Sensor Fusion and On-Line Monitoring of Friction Stir Blind Riveting for Lightweight Materials Manufacturing

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4052907 ◽

2021 ◽

pp. 1-36

Author(s):

Zhe Gao ◽

Haris Khan ◽

Jingjing Li ◽

Weihong Guo

Keyword(s):

Sensor Fusion ◽

Failure Modes ◽

Processing Parameters ◽

Data Driven ◽

Structure Property ◽

Cross Sectional ◽

Friction Stir ◽

In Situ Data ◽

Lap Shear

Abstract This research focused on developing a hybrid quality monitoring model through combining the data driven and key engineering parameters to predict the friction stir blind riveting (FSBR) joint quality. The hybrid model was formulated through utilizing the in-situ processing and joint property data. The in-situ data involved sensor fusion (force and torque signals) and key processing parameters (spindle speed, feed rate and stacking sequence) for data-driven modeling. The quality of the FSBR joints was defined by the tensile strength. Further, the joint cross-sectional analysis and failure modes in lap-shear tests were employed to confirm the efficacy of the proposed model and development of the process-structure-property relationship.

Download Full-text

The Use of Bobbin Tools for Friction Stir Welding of Aluminium Alloys

Materials Science Forum ◽

10.4028/www.scientific.net/msf.638-642.1179 ◽

2010 ◽

Vol 638-642 ◽

pp. 1179-1184 ◽

Cited By ~ 31

Author(s):

Philip L. Threadgill ◽

M.M.Z. Ahmed ◽

Jonathan P. Martin ◽

Jonathan G. Perrett ◽

Bradley P. Wynne

Keyword(s):

Mechanical Properties ◽

Grain Size ◽

Friction Stir Welding ◽

Cross Section ◽

Axial Force ◽

Aluminium Alloys ◽

Processing Parameters ◽

Machine Design ◽

Friction Stir ◽

Triangular Zone

The use of a double sided friction stir welding tool (known as a bobbin tool) has the advantage of giving a processed zone in the workpiece which is more or less rectangular in cross section, as opposed the triangular zone which is more typically found when conventional friction stir welding tool designs are used. In addition, the net axial force on the workpiece is almost zero, which has significant beneficial implications in machine design and cost. However, the response of these tools in generating fine microstructures in the nugget area has not been established. The paper presents detailed metallographic analyses of microstructures produced in 25mm AA6082-T6 aluminium wrought alloy, and examines grain size, texture and mechanical properties as a function of processing parameters and tool design, and offers comparison with data from welds made with conventional tools.

Download Full-text

Influence of hybrid ratio and friction stir processing parameters on ultimate tensile strength of 5083 aluminum matrix hybrid composites

Composites Part B Engineering ◽

10.1016/j.compositesb.2016.02.056 ◽

2016 ◽

Vol 93 ◽

pp. 26-34 ◽

Cited By ~ 24

Author(s):

Halil Ibrahim Kurt

Keyword(s):

Tensile Strength ◽

Ultimate Tensile Strength ◽

Friction Stir Processing ◽

Hybrid Composites ◽

Aluminum Matrix ◽

Processing Parameters ◽

Friction Stir

Download Full-text

Fundamental Aspects, Mechanical Behaviour and Mathematical Understanding of Friction Spot Stir Welds: A Review

Studies of Applied Economics ◽

10.25115/eea.v39i11.5963 ◽

2021 ◽

Vol 39 (11) ◽

Author(s):

Arash Fattahi ◽

E.E. Supeni ◽

M.K.A. Ariffïn ◽

M.R. Ishak ◽

Sahar Zolfaghari ◽

...

Keyword(s):

Spot Welding ◽

Mechanical Performance ◽

Processing Parameters ◽

Friction Stir Spot Welding ◽

Mathematical Understanding ◽

Environmental Conservation ◽

Service Industries ◽

Effective Control ◽

Friction Stir ◽

Welding Processes

The energy-saving and environmental conservation are increasingly important issues in manufacturing and service industries worldwide that have received considerable attention in recent years. Most importantly, this process eliminates the grain solidification errors generated by the standard fusion process. Thus, in this papers types and methods of stir welding will be explained and discussed accordingly . Friction stir spot welding is a tunable method as it allows an effective control and amendment of processing parameters using refill and powder-assisted schemes that can solve the problem of the keyhole and mechanical weaknesses in the joining of light metals processed by conventional Friction stir spot welding. This comprehensive review mainly focuses on the fundamental aspects of Friction stir spot welding processes and their impacts on the microstructural features and mechanical performance and mathematical understanding of various similar and dissimilar systems. To conclude, the challenges in further modification of Friction stir spot welding and future outlooks in different engineering applications are presented.

Download Full-text

Friction Stir Welding of AZ31B Magnesium Alloy with 6061-T6 Aluminum Alloy: Influence of Processing Parameters on Microstructure and Mechanical Properties

Friction Stir Welding and Processing VIII ◽

10.1002/9781119093343.ch28 ◽

2015 ◽

pp. 259-266 ◽

Cited By ~ 1

Author(s):

B. Mansoor ◽

A. Dorbane ◽

G. Ayoub ◽

A. Imad

Keyword(s):

Mechanical Properties ◽

Aluminum Alloy ◽

Friction Stir Welding ◽

Magnesium Alloy ◽

Processing Parameters ◽

Az31b Magnesium Alloy ◽

Friction Stir ◽

Microstructure And Mechanical Properties

Download Full-text

Effect of Friction Stir Processing Parameters on the Properties of AA7075-T73/Al2O3 Surface Metal Matrix Composite

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1002.140 ◽

2020 ◽

Vol 1002 ◽

pp. 140-150

Author(s):

Ali H. Al-Helli ◽

Ahmed R. Alhamaoy ◽

Ayad Murad Takhakh

Keyword(s):

Friction Stir Processing ◽

Particle Distribution ◽

Surface Hardness ◽

Base Material ◽

Processing Parameters ◽

Optical Microscope ◽

Friction Stir ◽

Surface Composite ◽

Surface Metal ◽

Number Of Passes

Friction Stir Processing (FSP) technology was wielded to output the Al7075/ Al2O3 surface composite. The effects parameters of processing method on particle distribution have been studied. The microstructure and mechanical characteristics of the samples were examined using the optical microscope, SEM and hardness examination. Acquired consequences, showed that Al2O3 particles were in a good interior distribution inside the basement. This technique produced excellent bonding between the surface composite and the base material. On other hand the surface hardness was increased about 25% as compared with the substrate. In addition, grain matrix refinement and enhanced particle distribution were obtained after each FSP pass. Also the dispersion of Al2O3 particles in the stirred area became more homogeneous and the average hardness improved by increasing the number of passes.

Download Full-text